Aluminium compounds for producing vinylic polymers

ABSTRACT

An enolate functionalized reaction intermediate of general formula (I), wherein X is an alkyl group; Z is selected from the group consisting of alkyl, hydrogen, halogen, alkoxy, thiol, aryloxy or ester; n is an integer and is at least one; Y is alkyl or H; the tetradentate ligand around the Al is optionally substituted. Also claimed is a process for the preparation of the enolate functionalized reaction intermediate and its reaction with a vinylic monomer and a Lewis acid to produce the corresponding vinylic polymer.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. Ser. No.09/750,220, filed Dec. 29, 2000 now U.S. Pat. No. 6,469,190, and whichis a continuation of International Application No. PCT/GB99/01771, filedJun. 4, 1999. These applications, in their entirety, are incorporatedherein by reference.

A COMPOUND

The present invention relates to an enolate functionalised reactionintermediate, a method for its preparation and a vinylic polymerproduced from reaction of said enolate functionalised reactionintermediate with vinylic monomer. Living or immortal polymerisation isa type of polymerisation that does not terminate naturally. Eachinitiator molecule produces one growing chain such that the polymergrows linearly with time. Therefore the degree of polymerisation can becontrolled to some extent. This method has been developed by Inoue forthe living polymerisation of both methacrylates and acrylates usingaluminium porphyrins, of the general formula (TPP)AIX, as initiatorswith irradiation from a xenon arc (Polym. Prepr. Jpn. (English Edition)1992, 41, E93(IIID-06) and E96(IIID-12).

(TPP)AIX where X=CH₃ or SCH₂CH₂ CH₃At ambient temperature each (TPP)AIX molecule was found to generate apolymer chain and excellent control of molecular weight was achieved.

Subsequently Inoue discovered that the further addition of a Lewis acidgreatly enhances the-rate of propagation. For example (TPP)AIMeinitiated polymerisation of methylmethacrylate (MMA), in the presence ofirradiated light, was found to yield 6.1% polymethylmethacrylate after2.5 hours. With the addition of a Lewis acid, for example a bulkyaluminium phenoxide, there was quantitative polymerisation within 3seconds. More recently Inoue has disclosed such systems where thepresence of irradiated light is not required. For example (TPP)AIX,where X=SPropyl, initiated polymerisation of MMA in the presence of aLewis acid, where there is complete monomer conversion after 1.5 minutesat 80° C. (T Kodeira and K Mori, Makromol. Chem. Rapid Commun. 1990, 11,645). However the molecular weights that have been produced with thissystem have been low, for example 22,000.

It is reported, by Inoue, that the initial reaction is of the (TPP)AIXcomplex with monomer to form an enolate initiator as the reactionintermediate, in the presence of irradiated light. This enolate can thenreact with further monomer in the presence of the Lewis acid to developthe polymer chain.

It is an object of the present invention to provide an enolatefunctionalised reaction intermediate, a method for its preparation and avinylic polymer produced from reaction of said enolate functionalisedreaction intermediate with vinylic monomer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 and FIG. 2 are ¹NMR spectra for the enolate of Example 4 .

Accordingly in a first aspect the present invention provides an enolatefunctionalised reaction intermediate of general formula (I)

wherein X is an alkyl group; Z is selected from the group consisting ofalkyl, hydrogen, halogen, alkoxy, thiol, aryloxy or ester; n is aninteger and includes n=0; Y is alkyl or H; the tetradentate ligandaround the Al is optionally substituted

In a second aspect, the present invention provides a process for thepreparation of an enolate functionalised reaction intermediate ofgeneral formula (I) wherein X is an alkyl group; Z is selected from thegroup consisting of alkyl, hydrogen, halogen, alkoxy, thiol, aryloxy orester; n is an integer and includes n=0; Y is alkyl or H, thetetradentate ligand around the Al is optionally substituted whichprocess comprises the steps of

-   (i) Preparing a Metal Complex of General Formula (II),    where R is a leaving group, in a solvent-   (ii) Preparing a metal enolate of a monomer, selected from the group    consisting of (alk)acrylic acids or alkyl esters thereof, in a    second solvent-   (iii) Mixing the two solutions of (i) and (ii) together-   (iv) Isolating the enolate functionalised reaction intermediate

In a third aspect the present invention provides a vinylic polymer whichis prepared from the reaction of an enolate functionalised reactionintermediate of general formula (I) with a vinylic monomer and a Lewisacid of general formula (III)

wherein at least one of C, D or E is capable of forming a co-ordinationbond with Al of the enolate functionalised reaction intermediate, theothers of C, D or E are bulky groups and M is selected from the groupconsisting of aluminium, magnesium, zinc and boron.

In the enolate functionalised reaction intermediate (I) X is preferablyan alkyl group ranging from C₁-C₂₀. For Z by thiol we mean both SH andSR¹ groupings where R¹ includes alkyl, ester, ether, Z is preferablyalkyl or hydrogen. Where Z may be alkyl it is preferably C₁-C₈ alkyl,more preferably methyl, n is preferably in the range 1 to 10, morepreferably 1 to 5. When Y is an alkyl group it is preferably C₁-C₂₀ ,more preferably C₁-C₂. Optional substitution is preferably on the twoaromatic rings of the tetradentate ligand around Al, more preferablysubstitution is of two tertiary butyl groups on each of these twoaromatic rings.

In the process of the present invention the metal complex is of ageneral formula (II) where R is preferably chosen from the groupconsisting of alkyl, halogen, alkoxy, thiol, aryloxy or ester. Thetetradentate ligand around the Al may be optionally substituted.Optional substitution is preferably on the two aromatic rings of thetetradentate ligand around the Al, more preferably the substitution isof two tertiary butyl groups on each of these two aromatic rings.Preferably the ratio of number of moles of metal complex (II) to molesof the metal enolate of a monomer, selected from the group consisting of(alk)acrylic acids or alkyl esters thereof is 1:1.

In the third aspect of the invention the bulky groupings in the Lewisacid (III) are preferably the same, in particular phenoxide or asubstituted phenoxide or thiolate; The one of C, D or E which is capableof forming a co-ordination bond with the Al of the enolatefunctionalised reaction intermediate is preferably chosen from the groupconsisting of alkyl, halogen, alkoxy, aryloxy and ester, more preferablyit is an alkyl group and more specifically methyl. M is preferablyaluminium.

The vinylic polymers that can be produced according to this inventioninclude homo and copolymers of the corresponding vinylic monomers suchas alkyl (alk)acrylic acid and esters thereof, functionalisedalkyl(alk)acrylic acid and esters thereof, for example hydroxy, halogen,amine functionalised, styrene, vinyl acetates, butadiene, olefins orolefinic oxides. By (alk)acrylic, we mean that either the alkacrylic orthe analogous acrylic may be used. For both homo and copolymers themonomers are preferably alkyl (alk)acrylic acid and esters thereof, morepreferably alkyl(meth)acrylates. These polymerisations can be conductedin such a way that architectural copolymers, for example block, ABA andstars, can be produced.

For both homo and copolymers the monomers are preferably alkyl(meth)acrylates. The ratio of number of moles of vinylic monomer tomoles of enolate functionalised reaction intermediate is preferably from1:1 to 20000:1. The ratio of the number of moles of enolatefunctionalised reaction intermediate to number of moles of Lewis acidpreferably ranges from 1:0.1 to 1:100, more preferably from 1:0.2 to1:10.

Polymerisation can be undertaken in the presence of a solvent, forexample toluene, dichloromethane and tetrahydrofuran, or in the bulkmonomer. The polymerisation is preferably undertaken at between −100 and150° C., more preferably between −50 and 50° C., in particular between15 to 40° C.

The present invention is illustrated by reference to the followingexamples.

EXAMPLE 1

Preparation of N,N′ ethylenebis (3,5-di-tertbutylsalicylidene imine)

A solution of 3,5-di-tert-butylsalicylaldehyde (3 g, 12.8 mmol) inethanol (150 ml) was prepared. To this ethylene diamine (0.43 ml, 6.4mmol) was added via syringe with stirring. The solution was heated toreflux for 15 minutes then allowed to cool to room temperature to allowcrystals of N,N′ ethylenebis (3,5 di-tertbutylsalicylidene imine) todevelop. These were isolated by filtration.

EXAMPLE 2

Preparation of N,N′ ethylenebis (3,5-di-tertbutylsalicylidene imine)Chloro Aluminium (Compound of General Formula (II))

A solution of dimethylaluminium chloride in toluene (6.1 ml, 6.1 mmol)was added dropwise to a solution of N,N′ ethylenebis(3,5-di-tertbutylsalicylidene imine) (3 g, 6.1 mmol) in toluene (40 ml).The product precipitated out of solution. The suspension was furtherstirred for 12 hours and the liquor removed to leave a powdery solid ofN,N′ ethylenebis (3,5-di-tertbutylsalicylidene imine) chloro aluminium.

EXAMPLE 3

Preparation of Lithium Enolate of Tert-butyl-isobutyrate

n-butyllithium (1.6M in hexane, 1.13 ml, 1.18 mmol) was added dropwiseat −78° C. over 15 mins to a solution of diisopropylamine (0.25 ml, 1.81mmol) in diethylether (20 ml). The resulting solution was added dropwiseat −78° C. over 5 mins to a solution of tert-butyl-isobutyrate (0.32 ml,1.81 mmol) in diethylether (20 ml) to form the lithium enolate oftert-butyl-isobutyrate.

EXAMPLE 4

Preparation of N,N′ ethylenebis (3,5-di-tertbutylsalicylidene imine)Enolate of Tert-butyl-isobutyrate Aluminium (Compound of General Formula(I))

The solution of lithium enolate of tert-butyl-isobutyrate, as preparedin Example 3, was added dropwise to a solution of N,N′ ethylenebis(3,5-di-tertbutylsalicylidene imine) chloro aluminium (1 g, 1.8 mmol),as prepared in Example 2, in tetrahydrofuran (50 ml) at −78° C. Thereaction solution was allowed to warm to ambient temperature and stirredfor 12 hours. The volatiles were removed by vacuum and the productextracted into pentane (10 ml), filtered and allowed to crystallise as ayellow-orange microcrystalline solid.

The structure was confirmed by ¹H NMR at 250 MHz on a Bruker AC-250machine as shown in FIGS. 1 and 2.

EXAMPLE 5

Preparation of Polymethylmethacrylate (PMMA)

A solution of methylmethacrylate (MMA) (1 g) in toluene (2 ml) wasprepared in a flask under nitrogen. Into a second flask N,N′ ethylenebis(3,5-di-tertbutylsalicylidene imine) enolate of tert-butyl-isobutyratealuminium, as prepared in Example 4, (33.4 mg, 0.05 mmol) andmethylaluminium bis (2,6-di-tert-butyl-4-methylphenoxide) (72.0 mg, 0.15mmol) were added. The solutions of both flasks were mixed and stirredfor 5 mins. Methanol (0.5 ml) was added to quench the reaction followedby toluene (2 ml). The PMMA was precipitated on addition to a 10 foldexcess of acidified (1% concentrated hydrochloric acid) methanol. It wasthen isolated by filtration. The yield was 90.1% of PMMA.

The PMMA polymer had an actual molecular weight of 32.700 compared tothe calculated value of 20,000. The polydispersity was 1.10 and thepercentage syndiotacticity was 74%.

1. A method for making a vinylic polymer comprising reacting together i)an enolate functionalized reaction intermediate represented by thefollowing formula (I)

wherein X is an alkyl group; Z is selected from an alkyl, hydrogen,halogen, alkoxy, SH, SR′ where R′ is alkyl, or aryloxy radical; n=0 to10; Y is alkyl or H; the tetradentate ligand around the Al is optionallysubstituted with alkyl groups on each of the aromatic rings; (ii) avinylic monomer: and (iii) a Lewis acid represented by the followinggeneral formula (III)

wherein at least one of C, D or E is capable of forming a co-ordinationbond with Al of the enolate funcitonalised reaction intermediate, theothers of C, D or E are bulky groups and M is selected from aluminum orboron.
 2. A method of making a vinylic polymer as claimed in claim 1wherein the vinylic monomer is chosen from alkyl(alk)acrylic acid andesters thereof, functionalized alkyl(alk)acrylic acid and ester thereof.3. The method of claim 1 wherein the ratio of number of moles of vinylicmonomer to moles of enolate functionalized reaction intermediate is from1:1 to 20000:1.
 4. The method of claim 1 wherein the ratio of the numberof moles of enolate functionalized reaction intermediate to number ofmoles of Lewis acid ranges from 1:0.1 to 1:100.
 5. The method of claim 2wherein the ratio of the number of moles of enolate functionalizedreaction intermediate to number of moles of Lewis acid ranges from 1:0.1to 1:100.
 6. The method of claim 3 wherein the ratio of the number ofmoles of enolate functionalized reaction intermediate to number of molesof Lewis acid ranges from 1:0.1 to 1:100.
 7. The method of claim 2wherein the ratio of number of moles of vinylic monomer to moles ofenolate functionalized reaction intermediate is from 1:1 to 20000:1 . 8.A method for making a vinylic polymer comprising reacting together i) ancomplex represented by the following formula (I):

 wherein: X is an alkyl group; Z is selected from an alkyl, hydrogen,halogen, alkoxy, SH, SR′ where R′ is alkyl or aryloxy radical; n=0 to10; Y is alkyl or H; and the tetradentate ligand around the Al isoptionally substituted with alkyl groups on each of the aromatic rings;(ii) a vinylic monomer; and (iii) a Lewis acid represented by thefollowing general formula (III)

wherein at least one of C, D or E is capable of forming a co-ordinationbond with the Al atom of the compound of formula I, the others of C, Dor E are bulky groups and M represents aluminum.